Combined paper carton and plastic bottle filling machine



May 21, 1968 DUDDLESTON ET 3,383,829

COMBINED PAPER CARTON AND PLASTIC BOTTLE FILLING MACHINE Filed Feb. 2, 1966 v 3 Sheets-Sheet 1 ll 22 ame 355 I 4 a0 v ":1" m1? lfi Z5 1 I3 r 7 ill 8727 a a; v

% MUM-- v i BY Aa/VA/PD E 63422527 May 21, 1968 DUDDLESTQN ET AL 3,383,829

COMBINED PAPER CARTON AND PLASTIC BOTTLE FILLING MACHINE 3 Sheets-Sheet 2 Filed Feb.

INVENTORS d4/14E8 M .DUDDLfIU/V, BY HOWARD 2. 6222527 fwn/ y 21, 1968 J. M. DUDDLESTON ET 3,383,829

COMBINED PAPER CARTON AND PLASTIC BOTTLE FILLING MACHINE 3 SheetsSheet 5 KZQO -ZFZ Filed Feb. 2, 1966 L ZQ.?

III

INVENTORS United States Patent 3,383,829 COMBINED PAPER CARTON AND PLASTIC EUTTLE FILLING MAiZHINE James M. Duddleston, 3282 Owasso Heights, St. Paul,

Minn. 55112, and Howard B. Garrett, 682 Oak St.,

Woodstock, Ill. 60098 Filled Feb. 2, 1966, Ser. No. 524,518 13 Claims. (CI. 5355) The present invention is directed to a combined former, filler and sealing machine and more particularly to an improved machine of this type utilized in connection with packaging liquids which is particularly adaptable to handle a plurality of sizes and shapes of cartons and containers.

In the field of packaging liquids, it is known to form a carton or container, to condition the carton or container for filling and to fill and seal the same with a liquid tight seal. This is particularly true in the milk industry in which cartons are formed from paperboard blanks which are erected to carton shape, sealed on the bottom thereof, and thereafter filled through the top and sealed at the top. Further, such machines are arranged to handle a plurality of sizes of the same carton shape and same material. With the advent of the usage of a plastic milk bottle in the milk industry, a problem has arisen for dairy operators in connection with equipment which Will handle, that is fill and close, both the presently used thermoplastic coated paperboard milk carton and the newly introduced plastic bottle. At present, separate equipment is required to handle, that is fill and seal, such cartons or containers. In addition, most dairies purchase the paperboard milk carton in flattened form and require forming machinery to erect the carton to the proper shape preparatory to filling and sealing. Space requirements, cost, maintenance and the the number of operators for such equipment have made it unfeasible for the general dairy operator and particularly the small dairy operator to utilize all types of milk containers. The present invention is directed to a simplified machine which will form flattened carton blanks into erected pap-erboard cartons, and which will also fill and seal the same with provisions for additionally handling the plastic milk bottle or container which is purchased in an erected form or formed on the premises in a separate machine. The use of a single filling machine through which the fluid or milk to be bottled is passed simplifies the overall structure. The improved machine provides a dual input to the filler sealer without further modification, and the filler sealer is provided with a capping mechanism so that plastic cartons and plastic bottles or containers may be filled and sealed thereby. The plastic bottles are sealed by capping where the cap is added to close the container. In the improved single composite machine, means are provided for synchronizing the operation of the former and filler or the conveyer which acts as the source for the plastic bottles with the filling machine so that a single operator need only load the blanks or bottles to the apparatus. Thus the filling mechanism or machine includes both the paperboard carton fold and sealer unit with the heater mechanism to facilitate sealing of the same and a capping mechanism which may be selectively placed in operation in the filler and automatically operated therewith. As such, the apparatus will not impede the fiow of containers or cartons in the sealing or capping function through the filling portion of the machine whenever the type of container being filled does not require the particular sealing mechanism not in use. In addition the filling mechanism is provided with a supervisory control over the former and the source or conveyer for the plastic bottles so that the conveyer or the former will be operated at a speed to permit the filler to receive and fill all of the units. Further, the sources of the containers and cartons, in addition to being slaved to the filler, are interlocked therewith at the capping and sealmg portions therein to properly close out the carton and/ or bottle and de-energize the apparatus not in use. Wherever the speed of the source, such as the former or the conveyer, is a controlling factor, that is, is slower in operation than the filling and sealing machine, particularly for the smaller sized cartons, the improved apparatus permits the sealing and capping mechanism together with the filler to be slaved thereto. In the improved forming, filling and sealing apparatus, the filling machine or the portion thereof which seals the cartons, namely the heater, fold guides and clamping mechanism are mounted such as to be moved out of the way of bottles moving through the filling machine on the conveyer of the filling machine so as not to obstruct bottle flow therethrough, and, similarly, the capping mechanism is similarly mounted on the filler structure to provide the same operation whenever plastic coated paperboard cartons are being filled and sealed.

Therefore it is the object of this invention to provide an improved former, filler and sealing machine.

Another object of this invention is to provide in a former, filler and sealer machine provisions for feeding an alternate source of containers to the filling machine.

A further object of this invention is to provide a former, filler and sealing machine particularly used in the milk industry to handle both plastic coated paperboard cartons in flattened form and formed plastic bottles.

A still further object of this invention is to provide a former, filler and sealing machine which will handle various sized paperboard cartons, and various sized plastic bottles, and which will cap and/or seal the respective containers depending upon the type of the same.

It is also an object of this invention to provide in a machine of this type means for controlling either the forming, filling or conveying portion of the same in accord with the speed of the slowest machine for synchronization purposes.

Another object of this invention is to provide a machine of this type which insures that the proper sealing or closing apparatus is in operation for the type of container fed into the filling machine.

These and other objects of this invention will become apparent from a reading of the attached description together with the drawings wherein:

FIGURE 1 is a perspective View from the front of the improved forming, filling and sealing machine.

FIGURE 2 is a top view of the improved forming, filling and sealing machine.

FIGURE 3 is a side elevational view of the improved forming, filling and sealing machine with parts removed.

FIGURE 4 is a back view of the improved forming, filing and sealing machine, and

FIGURE 5 is a schematic wiring diagram for the improved forming, filling and sealing machine.

The improved carton forming, filling and sealing machine of the subject invention provides a simplified and compact arrangement of parts by means of which containers for a liquid may be formed and transferred in erected form to a filling machine which is capable of filling and sealing cartons of varied types and shapes. Thus the improved carton forming, filling and sealing machine of the present invention will erect carton blanks of a paperboard material with a thermoplastic coating from a flattened form to a completed carton and transfer the same to the filling and sealing portion of the same which is synchronized for simultaneous operation therewith. In addition, the filling and sealing machine may receive preformed plastic bottles which may be filled and capped to seal the same, thereby providing versatility, simplicity and compactness in an overall machine which will enable the usage of varying types of containers in a filling and sealing operation. Such varied carton sizes and shapes are presently in use in the dairy industry and it is of extreme advantage to the dairy operator to have a single piece of apparatus which will handle, that is form and fill, the various types of containers presently employed for the packaging of milk. Thus the improved forming, filling and sealing machine will handle the foldable plastic coated paperboard cartons such as to form and fill the same and plastic bottles currently in use in this industry. The resultant saving in space and equipment investment together with the labor is of extreme advantage for the dairy operator.

The improved forming, filling and sealing machine is shown herein in general form and only the modifications thereto to facilitate the dual input to the filler and the correlation between the varied sources of containers with the filler is specifically disclosed. Therefore the drawings show in perspective a combined former, filler, sealer and conveying apparatus interconnected and operated to provide a dual source of containers for the filler, sealer and apparatus thereon for suitably filling and sealing the same. The forming portion of the apparatus is of the type shown in the co-pending application of Clarence G. Austin, Howard R. Garrett and Percy King Ser. No. 490,330, dated Sept. 29, 1965, and entitled Carton Forming Machine. It will be recognized, however, that the forming portion of the apparatus may take varied forms. Further the combination of the former and filling and sealing machine is generally shown in the corresponding application of Howard R. Garrett and Clarence G. Austin, In, Ser. No. 405,530, dated Oct. 21, 1964, and entitled Carton Forming and Filling Machine. The present invention is an improvement over disclosures of these apparatuses and only the general details of the respective machines are disclosed herein, it being understood that the specific details may be found in the above identified patent applications. Therefore, as disclosed in FIGURES 1 and 2, the improved forming, filling and sealing machine includes a forming portion, identified generally at 10, a filling and sealing portion, identified generally at 15, and a conveying portion, identified generally at 20. The forming portion shown herein is of the type adapted to receive carton blanks in flattened form and erect them to a carton adapted to be filled by the filling machine. Such cartons are of the type shown in the Egleston et al. Patent No. 3,120,335, dated Feb. 4, 1964, and entitled Container With Infolded Bottom Closure. These cartons are available in flattened form and are covered with a thermoplastic coating on all surfaces thereof which coating is softened through heating and sealed through pressure to provide a liquid tight enclosure. A similar type of forming machine is shown in the patent to M. A. Terry No. 3,064,542 dated Nov. 20, 1962, and entitled Carton Forming Machine. Varying sized paperboard cartons are generally used and the former which is shown in the co-pending application Ser. No. 490,330, is adapted to form the varying size paperboard cartons. Such a machine generally includes, as will be seen in FIGURES l and 3, a basket section 22 for retaining the flattened carton blanks, an opening and erection section 24 which is adapted to open the carton blanks from the flattened form and erect or position the same at a section 28 on a plurality of mandrels 25 mounted on a spindle 26 which is pivotally journaled on the frame 30 of the forming machine for rotation about a generally horizontal axis in a vertical plane. The mandrels 25 are normally adjustable to receive and form varying sized cartons, as identified in the before mentioned application, and the cartons when erected on the mandrel in an inverted form have the bottom flaps of the same bent or creased at a forming section, indicated at 32, preparatory to forming the bottom of the carton. The bottom flaps are then heated at a gas type heater, indicated at 35, while the carton blank is positioned on the mandrel and the spindle is then rotated to a section or station which folds the flaps, as indicated at 36, and seals the bottom of the same, as indicated at 33, while precreasing the top flaps through apparatus to prebend the same preparatory toward filling of the carton. The carton blanks are then removed from the mandrel by a removal structure 42 and positioned in an upright form on the filling portion 15 of the machine preparatory to filling the same. The spindle 25 with the mandrels 25 thereon are driven through suitable means in a stepped type sequence of motion and the individual working stations, such as the carton opening section 24, the carton erection section 23, the flap folding section 32, the flap folding section 40 and the carton removal section 42 are operated simultaneously through the same motive system with hydraulic actuators controlled through the same solenoid as will be later identified. Similarly, the press section 36 sealing the bottom of the carton is operated in a stepped function delayed from the remaining carton forming stations as is also the drive apparatus for the spindle which indexes in a stepped sequence of operation. The details of such a machine perform no part of the present invention and it will be recognized that other types of formers may be used in the improved combined forming and filling machine within the scope of the present invention. Such a former, however, must be operated in the same type of sequence of operation as the filling machine and the conveying apparatus which is connected to and associated with the filler must also be similarly sequenced such that they may be interconnected and synchronized in operation. Thus, in the forming portion 10 of the improved machine, the apparatus is hydraulically operated through suitable motive means (not shown) with the control sequence being effected by solenoid type actuators, operating valves in a hydraulic circuit. A single solenoid will effect the majority of the carton forming functions simutlaneously and the press and index portion of the former which indexes or moves the spindle in the stepped sequence of operation will be delayed slightly therefrom. Such stepped and automatic sequence of control is initiated by completion of operation of the carton forming sections as evidenced by the energization of a solenoid actuator, indicated generally at in the circuit diagram of FIGURE 5, which will cause stepping of the press return actuator 52 shown in FIG- URE 5 to initiate the cycle of operation. The interconnection of the machine will be effected at this point, as will be hereinafter noted.

The filler sealer portion 15 of the improved machine is shown generally in FIGURES 1-4 as incorporating a frame having a table-like top 62 upon which are positioned a plurality of upstanding support members or upright members 63 and side rails 65 which define a centrally located guide channel across the surface of the table. The filler machine includes a conveying apparatus in the form of a bar type actuator mechanism 68 with carton engaging fingers 70 thereon (see FIGURE 4) to slide the carton or containers across the surface of the table in a conventional manner. The containers, in such movement, will be guided by the rails 65 and upright members 63 which define the channel and which is adjustable in width and height to accommodate varying sized cartons in a manner conventional with such machines. The filler includes a filler tank 70 and appropriate valves '73, 74, '75 through which fluids, such as milk, are valved from the tank into the containers to be filled. The structure includes a suitable timing control for initiating and timing the operation of the various portions of the filling machine such as the valves, the conveying apparatus as evidenced by the bar 68 through a suitable motive means (not shown) and the operation of a capping mechanism 82 as well as a clamping or sealing mechanism 83 which close respectively bottles and cartons. In the closure of the cartons, the structure includes a suitable heating apparatus having a heating control 85 and appropriate guide rails 87 which fold the flaps of the carton after filling together with an appropriate clamping mechanism or jaws 88 which clamp and hold the heated top flaps of the carton blank for the purpose of sealing the same. The capping mechanism 82 includes a container 90 adapted to mount and store caps or covers to be positioned on the tops of the plastic bottles after filling for the purpose of completing the enclosure and sealing the same. Both the clamping mechanism 88 and the capping mechanism 82 are electrically operated through suitable solenoids, to be later defined, which along with the solenoid operated valves 73, 74, '75 are controlled by the timing mechanism in an appropriate control circuit suitably interlocked with the forming machine and conveying apparatus as will be hereinafter defined. The filling machine is generally of the type shown in the co-pending patent application Ser. No. 405,530 referred to above with improvements permitting the closing of the plastic bottle type containers and the mounting of the sealing and capping sections 83, 82 of the filling and sealing portion 15 of the improved machine. In this portion of the machine, the capping mechanism is supported through a suitable base structure 95 which is slidably mounted on the top 96 of the guide rails 65 and upright 63 forming the channel on the filling table such as to be moved out of the way of the channel for passage of the paperboard carton type containers. Similarly, the assembly including the heater 85, guide rails 87, and the clamping mechanism 88 are mounted on a base 100 and pivoted, as at 102, on one edge of the upstanding frame such as to be pivoted out of the way of the plastic bottles when the filling machine is filling and sealing this type of container.

The fillin portion of the combined machine is normally positioned at right angles to the forming portion so that its input end is adjacent the output end of the forming portion of the machine, such as is shown in top view in FIGURE 2. Thus cartons are discharged from the forming portion onto the input end of the filling machine or at the table level of the frame wherein the conveying portion of the filling machine, that is the arm 68 with the fingers 70 thereon, engage and move the formed cartons through the filling machine for filling and sealing of the same. Also connected to the input end of the filling machine is a conveying apparatus adapted to convey formed plastic bottles to the filling and sealing portion of the machine. As will be seen in FIGURES 2 and 4, the conveying apparatus is mounted on a support or frame structure 110 positioned beside the forming portion 10 of the machine such that the conveyer table part 115 and the operating or moving linkages or fingers 120 are at the level of the input to the filling and sealing portion 15. The plastic bottles are received from a source, such as is indicated in block at 125, which may merely be a starting table or a forming machine for plastic bottles. The conveying apparatus includes a motor or motive means indicated generally at 130 operating through a linkage system 135 to move the fingers 120 in a stepped sequence of operation to position bottles at the input end of the filling and sealing portion of the machine in a conventional manner, and in the same sequence as the preformed paper cartons are discharged from the forming portion 10 of the machine. It will be understood that in the improved forming, filling and sealing machine, that the machine will be conditioned to operate either with preformed paperboard cartons formed by the forming portion of the machine or, upon changeover, as receiving of plastic bottles from the source 125 by the conveying apparatus 20 to the input of the filling portion of the machine in which the plastic bottles are filled and capped. In one mode of operation, the capping mechanism is removed and the paperboard cartons are appropriately filled, heated, folded and the top gable fiaps of the same are sealed to complete the filled carton in a conventional manner. With the plastic bottles, the forming machine is de-energized and the capping mechanism is positioned to receive the filled bottles and. to cap the same with the flap heating, folding and clamping or sealing structure83 pivoted out of the way so as not to impede the passage of filled and capped plastic bottles through the filling portion of the machine. As the capping mechanism 82 and the sealing assembly 83 which includes the heating and folding portion of the same are moved out of the way, appropriate switches are operated in the control circuit to eliminate energization of the same. Further, the structures when moved into operative position are suitably attached through means (not shown) to secure the same thereon for operation on the appropriate containers.

The improved forming, filling and sealing machine is operated through suitable control circuitry shown in FIG- URE 5 which permits independent and selective operation of the former and filling portions 10 and 15 or the conveyer and filling portion 20 and 15 respectively depending upon the type of container being handled. Further the forming portion may operate independently of the filling machine and the conveying apparatus, as desired. Thus it will be seen that FIGURE 5 includes electrical circuitry for the conveying portion which is indicated generally at 140. This portion of the circuit includes energizing conductors 141, 142 having disconnected switches 138 in series circuit with the same and suitable stop-start manual switches 145, 146 connected across the same and to an energizing relay coil 148 having in series therewith an interlocking disconnect operated switch 150 which, when closed, indicates that the forming portion 10 of the apparatus is de-energized. The relay 143 includes a normally open holding contact connected in parallel across the manually operated switch or push button 145 in a conventional manner and a second normally open contact which is connected in series with a normally closed interlocking contact 162 of the filling portion 15 of the machine to a timer 165 having a motor 166. In this circuit the contacts 160, 162 are connected in series with a timer contact and the motor 166, with the circuit being completed to the supply conductor 142. An appropriate clutch mechanism 171 for the timer is connected in parallel with the timer contacts 170 and timer motor 166. Also included in this circuit and controlled by the timer contact 170, the filler contact 162 and the relay contact 160 in a series circuit is a relay coil 175 having a normally closed contact 176 positioned in the filling circuit, as will be hereinafter identified. Timer 165 includes single pole, double throw timing switches 17 8, 179 which control respectively solenoids 182, 183 of the operating motor 130 for the conveying mechanism. Thus, depending upon the position of the timing contacts 178, 179, the conveying mechanism will be operated in a forward or reverse manner to move the plastic bottles along a conveying bed and with the fingers 120 being pivoted out of the way through the linkage system 135 to pick up succeeding cartons and cause the movement of the plastic bottles through the conveying mechanism 26 in a stepped sequence of operation. It will be noted that the forward and reverse solenoids 182, 183 have in addition reversing micro-switches 185, 186 respectively in series therewith and a normally closed contact 181 is positioned in series with the forward solenoid 182 to reverse operation of the conveyer and synchronize the operation of the conveyer with the filling machine, as will be later defined. The relay 175 will be energized only during a predetermined sequence of timing operation such that its normally closed contact will interlock in the filling circuit in a manner to be later identified for the purpose of synchronizing the conveyer with the filling portion 15 of the machine.

The forming portion 10' of the machine has its control circuitry shown generally in block at 190 and energized from supply conductors 193, 194 with suitable disconnect switches 195 in series therewith controlling energization to a supply transformer 200 and an electric motor 201 driving the hydraulic portion of the former together with an electric motor 203 driving the vacuum pump for the former as disclosed in the above identified co-pending application. Switches 195 are ganged with switch 151 in a mechanical interlock type arrangement. Control contacts 205, 206 in series with the respective electric motors 201, 203 control the energization of power to the same. The details of the control circuit for the former are omitted for simplicity but the output of the control transformer includes an interlocking disconnect switch 210 which is ganged mechanically with disconnect switches 138 and is connected in series with the transformer secondary winding 208 energizing the control circuit. Thus, the control circuit for the former will not be energized except when the conveyor control circuit is de-energized. Similarly, as shown in block at 190, the control circuit includes a cylinder return solenoid 50 operating hydraulic circuitry which will complete the functions of the various portions of the forming machine prior to the return of the press through operation of its solenoid 52 to again initiate continuous operation of the former. A normally closed contact 215 is shown in series with the solenoid 50 which normally closed contact is included in the filling control circuit to indicate the appropriate electrical interlocking of the same for the purpose of synchronizing the former with the filling machine. A further interlocking contact 218 is shown in series with the solenoid 52 to indicate that the cylinder press will return only to its inactive position initiating operation of the former after completion of the operation of the remaining portions of the former. The details of the forming machine and its appropriate control circuitry will be found in the copending application Ser. No. 490,330 referred to above. It will be understood, however, that any type of forming machine may be utilized which is capable of stepped operation or a sequence of operation such that it may be sequenced with the filling portion of the machine.

The filling and sealing portion of the machine has its control circuitry shown generally at 220 with appropriate supply conductors 222, 224 supplying electrical power to the same. (Donnected across the power conductors is the heater element for the filler, shown generally at 230, which heater element has suitable manually operated disconnect switches 232 in series therewith and electrical interlocking contacts 234 further in series therewith to insure isolation of the same whenever the heater is not in use. The control circuitry is energized through manually operated switches 235 positioned in the supply conductors 222, 224 to supply power to the remaining portion of the machine which includes hydraulic motor 240 energized through a. manually operated contact 242 and connected in series therewith across the supply conductors 222, 224. Also included in this portion of the control circuit are the plurality of fill solenoids 243, 244 and 245 indicative of the three fill valves 73, 74, 75 in the filling and sealing machine. Each of these fill solenoids have connected in series circuit therewith a normally open switch contact indicated at 247, 248 and 249 respectively with the entire assembly being connected in a parallel circuit as evidenced by the conductors 258, 251 and across the supply conductors 222, 224 through a suitably connected relay contact 255 and a manually operable and normally open switch contact 260. The switch contacts 247, 248 and 249 are operated through sensor fingers which detect the presence of a container beneath the valve operated by the respective fill solenoids such that the solenoids will not be operated unless a container is beneath the valve and in a position to be filled. As such they are identified as no-carton, no-fill switch sensors conventional with filling machines. The relay contact 255 is operated by a relay coil 262 connected to the conductor 250' and in series circuit with a timer contact 266 to the conductor 224 to provide a power circuit for the fill solenoids which are in a parallel circuit with the timer contact and controlled thereby such that the timer contact does not have to carry the load current of the solenoids. The manually operated switch 266 provides that the fill solenoids will not be operated unless this switch is manually closed such that the fill and seal portion 15 of the machine may be operated mechanically without filling for maintenance and inspection purposes. In normal operation, switch 260 will be closed and the relay 262 will be energized to close the relay contact 255 placing the fill solenoids 243-245 in operation whenever a container is beneath the fill valve.

The remaining portion of the control circuit for the filling and sealing portion of the machine is energized at a lower voltage, it being understood that the conductors 222, 224 will normally be connected to a higher voltage supply to energize the heater 230 and motor 240. Thus for example, these conductors are connected to a 220 volt source and an auto transformer, indicated at 270, has the extremities of its windings connected to the conductors 222, 224 with a tap connection 272 of the same being connected to a conductor 275 which with the common conductor 224 will provide the low voltage portion of the control circuit. Across this low voltage portion of the control circuit is positioned the motor 277 of the timer to be continuously energized thereby whenever the switch contacts 235 are closed. The contact 266 is operated thereby in a timed relation as well as other contacts to be hereinafter identified. Also included in this low voltage portion of the circuit are a pair of disconnect relays 280, 281 which are energized whenever mechanically operated switches 283, 284 in series circuit therewith are closed. The switches 283, 284 respectively are limit switches associated with the base structures for the clamping mechanism, heater and folding portion of the filling and sealing machine and the capping portion of the filling and sealing machine. These switches are closed Whenever the respective components are placed down on the channel or the upright supports and guide rails 63 of the filling machine and locked in place for usage. Also in series with these switches and their coils are electrically interlocking contacts of the respective relays 280, 281 as indicated at 287, 288 respectively. Thus the relay coil 280 operated by limit switch contact 283 has in series therewith contact 287 which is of the normally closed type and is operated by relay coil 281. Similarly the relay contact 288 is a normally closed contact of the relay coil 280 and is positioned in series with the limit switch 284 and the coil 281 of the relay detecting positioning and operation of the capper. The electrical interlocking and the limit switches will insure that these devices may be operated simultaneously, that is be in a position to operate, since the closure of their switches 283, 284 respectively will attempt to energize the respective relay coils and the electrical interlocking will prevent such energization. Therefore only the capping mechanism will be energized whenever the switch 284 is closed and the heater, clamping mechanism and fold guide assembly will be operative whenever the switch 283 is closed, indicative of the fact that the base upon which they are mounted is locked in position for operation.

The timer for the filling and sealing machine Whose motor 277 is energized directly across the conductors 224 and 275 includes in addition to the timer contact 266 previously defined contacts 290, 291, 292 and a clutch coil 295 which operates to reset the timer contacts at the end of a timing cycle. Thus as will be seen in the circuit diagram, the timer contact 222, which is of the normally closed type, is connected in series circuit with the clutch coil 295 of the timer and a limit switch 300 on the table which indicates the carriage or conveyer mechanism for the bottles or cartons is in a forward position, that is it has moved bottles into position relative to the fill valves. Also controlled by timer contact 292 in a circuit parallel to the clutch coil and limit switch 300, is a relay coil 310 and the second timer contact 290 connected in series circuit. The relay coil 316 is a sequencing relay whose normally closed contact 215 is positioned in series with the cylinder advance solenoid for the former portion of the machine and a normally closed contact 181 in series circuit wtih the solenoid 182 controlling forward movement of the conveying portion 20 of the conveyer. The carriage mechanism on the filling and scaling machine is onerated through a pair of forward and reversing solenoids 315, 320 which operate the hydraulic mechanism to move the bar and fingers of the carriage conveyer for the containers on the table top of the filling and sealing machine. The forward solenoid 315 is energized through a circuit which includes a normally closed contact 321 of a relay coil 322 connected in parallel with the cylinder advance solenoid 50 on the forming machine. This circuit in addition includes a normally closed contact 176 of the relay coil 175 which is included in the conveyer energizing circuit and energized with the timer contact 170 or under control thereof. The normally closed contacts 321 and 176 form the synchronizing relays of the former and conveyer and are connected in series circuit with the timer contact 291 which initiates and primarily controls the energization of this carriage advance solenoid of the tiller. Also included in this circuit is a manually operated Switch contact 325 which places the filler in an automatic mode of operation. Thus the carriage forward solenoid 315 of the conveying portion of the filling and sealing machine is controlled through the sequencing contacts 321 and 176 to prevent the filler from operating faster than either the former or the conveyer should the latter be slower in operation and is initiated by the timer contact 291 whenever the manually operated switch 321 is closed placing the filler in an automatic mode of operation.

The carriage reverse solenoid is energized from a normally open contact 330 of the fill relay 262 in a series circuit connected across the conductors 224 and 275. Connected in parallel circuit with the carriage reverse solenoid is a solenoid 335 which operates the sealer clamp mechanism and a solenoid 340 which operates the capper mechanism. These individual solenoids are isolated by the contacts 336 of the disconnect relay 280 and the contacts 339 of the disconnect relay 281 which are energized respectively when the respective mechanism with which the solenoids are associated are placed in an operative position. Thus the sealer clamp solenoid 335 will be energized with the carriage reverse relay or solenoid 320 whenever the switch 283 is closed indicating that the assembly of the heater, flap guides and clamp are positioned on the guide rails of the filler table in an operating condition. Similarly the capper will be energized with the carriage reverse relay only when the disconnect relay 281 is energized through closure of the limit switch 284 and indicating that the capper mechanism is in position for operation on the filler .table and the disconnect relay associated with the heater, clamping mechanism and fiap guide structure is de-energized.

Operation In the improved forming, filling and sealing machine an apparatus is provided which will form the paperboard type cartons used in the milk industry to an erected carton and transfer it directly to a filling and sealing machine wherein they will be filled with a liquid, such as milk, and sealed through a heating process to soften the thermoplastic resin coating of the carton and a clamping process to cause the flaps of the same to adhere in a liquid tight package. In addition, the improved machine may receive plastic bottles which are directed to the input of the filling machine wherein they are filled and capped to complete the enclosure and provide a liquid tight seal. The improved machine provides for a forming portion and a filling and sealing portion as well as a conveying portion for the second source of containers in a simplified compact arrangement with the filling portion being utilized to fill both types of containers. It occupies a minimum amount of space and is capable of operation by a single operator. The improved machine will, upon operation of manual switches and a minimum of changeover, selectively operate as a former filler or as a conveyor filler for the varied types of containers. This increases the versatility of the apparatus and permits the dairy operator to use a minimum amount of equipment with a substantially decreased investment and minimum of space requirements for the same. The filling portion of the machine includes a capping mechanism 82 and a sealing clamping mechanism 83 which are so mounted on portions of the filling table so as to be selectively brought into operative relationship with the containers bein filled to seal the containers. The apparatus is controllably interlocked such that only the particular mode of operation being used will be controllably energized at any one time. By moving either the capping mechanism or the clamping sealing mechanism into proper position on the filling portion of the machine, the filler will be conditioned to operate and seal the respective type of carton for which the control is set. It further prevents inadvertent operation of the machine with the wrong type of closure mechanism in position on the filling portion of the machine.

With reference to the schematic diagrams, in the mode of operation of the machine in which the thermoplastic coated paperboard cartons are formed and filled, the conveyer portion or its control circuit 140 will be deenergized, that is its disconnect switch will not be operated. Therefore the respective components in these control circuits will be de-energized. In the former, the switch mechanism 195 will be closed and the appropriate control switches 210 in the control portion of the circuit will be closed when switches 138 are open such that the former will operate to remove carton blanks from the basket portion 22 of the former and erect them on the mandrels 25 thereof in a stepped sequence of operation. The cartons will be erected in an inverted position with the bottom flaps of the same creased or bent, heated through the heater 35, folded and sealed through its press 38 after which the formed carton will be removed by the carton removal mechanism 42 and placed on the input table of the filler in an inverted position ready for filling. In the automatic mode of operation of the former, with the appropriate manually operated switches (not shown) closed, the cylinder advanced solenoid and the press return solenoid 52 will be effectively energized and sequentially operated. Simultaneous with each sequence of operation, the control relay 322 will be periodically energized and operative in the control circuit of the filling and sealing portion of the machine as will be hereinafter described. For simplicity the details of the circuit together with the majority of the details of the former are omitted. It will be recognized that any type of former may be utilized for this purpose which operates in the same stepped or continuous type of operation such as to be capable to synchonization with the filling and sealing portion of the machine.

In the filling circuit, the manually operated switches 232, 235, 242, 260 and "325 will be closed to effect automatic operation of the same. With the positioning of the heating, clamping and folding assembly 83 in proper position on the filling portion of the machine and the positioning of the capping portion 82 in an out of the way relationship, the disconnect relay 280 will be energized through its switch 283 to close the power circuit to the heater 320 through the contacts 232, 234. Further the hydraulic motor 240 will be energized and the fill relay 262 will be conditioned for energization through contact 260 to condition the fill solenoids for operation with operation of the timer. The energization of the relay 262 will be selectively controlled through operation of the timer contact 266 such that the filler solenoids will be selectively operated or controlled by the presence of a carton underneath the control valves operated by the solenoids 24B, 244 and 245 as indicated by the operation of the switches 247, 248 and 249 respectively when timer contact 266 is closed. The low voltage portion of the control circuit will maintain the timer energized which timer will be operated through a predetermined sequence to open and close the switches 266, 292, 2% and 291 causing the filling operation, the carriage or the conveyer portion of the filler machine to reciprocate in a forward and reverse direction picking up cartons from the former and advancing them through the channel section of the filling machine on the tabletop 62 thereof beneath the filling valves and underneath the heating, flap folding and clamping mechanism. The timer operation will also energize the control relay 310 whose contact 215 is included in the former circuit to synchronize the same with the filling and sealing machine and prevent a difference in the speed of stepped operation of the same such that cartons will be continuously available to the filler in a prescribed rate or frequency. With the energization of the timer, the relay 262 will sequence in the same relationship closing the circult to the fill solenoids and also to the carriage forward solenoid 315. It will also provide operation or energization for the solenoid 335 energizing the sealer clamp through the disconnect contacts 336 of the relay 280. During this period of time, the contacts 339 of the capper will be open due to de-energization of the relay 281 which is indicative of the fact that the capper is not in the position to operate. A synchronized operation is provided for the former filler in which the slowest operating machine will slave or control the operation of the portion attempting to run faster such that an overall synchronization of the apparatus will be provided.

Whenever the plastic bottles or the second source of containers is to be used, the conveyer mechanism or portion 29 is energized through its control circuit and the former portion '10 of the overall machine is de-energized through opening of the switch contacts 195 for the control circuit 190. This will effectively de-energize this control circuit and the interlocking contacts in the conveyer will permit operation of the same. The conveyer will be operated, as indicated in the circuit 140, through closure of the disconnect switches 138 and the start switch causing energization of the control relay 148 which will effect a holding circuit around the manually operated start switch 145. It will also energize the timer of the conveyer and its clutch 171 to operate the switch contacts and 178, 179 controlling energization of the timer motor and the forward and reverse solenoids 182, 183 of the conveyer motor. The interlocking circuit 181 in the forward direction or in series with the forward solenoid 182 will synchronize the operation of the conveyer with the filling and sealing machine. Further the control relay through its normally closed contact 176 included in the control circuit for the carriage forward solenoid 315 of the filler will effectively synchronize the filler with the conveyer. Similarly the relay 310 in the filler circuit through its contact 162 in series with the timer 165 will synchronize the operation of the filler with the conveyer so that the conveyer will not supply containers or bottles to the filling machine faster than the filling machine can receive and move them through the same. The limit switches 185, 186 in series with the forward and reverse solenoids 182, 183 of the conveyer motor will effect reversal in direction of the conveyer motor only at the time when they reach the limits of travel. During this sequence of operation, the filler will operate in the same manner as that previously described to provide a stepped sequence of operation energizing the capper mechanism or solenoid 340 in place of the sealer clamp solenoid 335. During this condition of operation, the switch 283 to the disconnect relay 280 will be open dc-energizing the relay and isolating the heater 230 from the power supply as well as the sealer clamp 335. The closure of the limit switch 284 energizing the disconnect relay 281 of the capper will permit closing of the circuit to the capper solenoid 340 such that it may operate in synchronism to be simultaneously energized with the carriage reverse solenoid 320 for the filler.

This improved forming, filling and sealing machine provides a simplified and compact arrangement by means of which two sources of supply may be synchronized with the fillers in such a manner that one or the other may operate therewith and the slowest machine in the combination operating will control the overall operation for continuous and trouble-free forming, and/or conveying and filling and sealing of the respective types of containers. The apparatus may be placed into operation with a minimum amount of changeover making it readily available for usage with a minimum amount of operator time and changeover time.

Therefore in considering this invention it should be remembered that the present disclosure is intended to be illustrative only and that the scope of the invention should be determined by the appended claims.

What is claimed is:

1. A high-speed carton former, filler and sealer machine comprising: a forming machine adapted to form thermoplastic coated blanks of paperboard from carton blanks in a flattened condition to an erected condition by opening the blanks, bending and folding the bot-tom flaps of the same, heating and sealing the bottom flaps, and bending the top flaps of the erected carton preparatory to filling and sealing of the same; control means for controlling the operation of the carton forming machine in a stepped type of operation; a filling machine adapted to receive and fill said carton blanks including a filler mechanism, a heater and flap folder, a flap sealer, and a capping mechanism; a second control means for controlling the operation of the filling machine in a stepped type of operation; a conveyer adapted to supply the filling machine with an alternate source of containers which utilize the capping mechanism, third control means for operating the conveyer in a stepped type of operation; the second control means of the filling machine having a supervisory control included in part in the first and third control means to selectively limit the stepped operation of the forming machine and the conveyer in accord with the operation of the filler mechanism of the filler machine.

2. The high-speed carton former, filler and sealer machine of claim 1 and including additional controllers included in part in the first control means for the forming machine and in the third control means for the conveyer for controlling selectively the operation of the heater and flap sealer and the capping mechanism in accord with the selective operation of the forming machine and the conveyer respectively.

3. The high-speed carton former, filler and sealer machine of claim 2 in which the filling machine includes a conveying apparatus mounted on a frame which is adapted to move selectively erected carton blanks and containers to and beyond the filler mechanism for engagement selectively with the sealer and the capping mechanism which together with the heater and the flap folder are positioned on the frame above the conveying apparatus to engage both carton blanks and containers.

4. The high-speed carton former, filler and sealer of claim 3 in which the control means for the forming machine includes means for driving elements to perform the opening, bending, folding, heating and sealing function of the forming machine and an electric control circuit means for controlling the energization and operation of these elements in a predetermined sequence; and the control means for the filling machine includes means for operating the conveying apparatus, the filler mechanism, the heater, the sealer and the capping mechanism and an electric control circuit means for controlling the energization and operation of the stated means of the filling machine in a predetermined sequence.

5. The high-speed carton former, filler and sealer machine of claim 4 in which the capping mechanism and the combination of the heater, flap folder and sealer are pivotally mounted on the frame of the filling machine and adapted to be pivoted out of contact with carton blanks and containers on the conveying apparatus.

6. The high-speed carton former, filler and sealer machine of claim 5 and including switch means included in the electric circuit of the capping mechanism, the heater and the sealer to prevent their energization when they are pivoted out of contact position with respect to the conveying apparatus.

7. The high-speed carton former, filler and sealer machine of claim 6 in which the capping mechanism includes a container adapted to hold and supply caps to the capping mechanism to complete and close containers filled by the filler mechanism.

8. The high-speed carton former, filler and sealer machine of claim 7 in which the electric control circuit means for-the filling machine and the forming machine include adjustable timing controllers adapted to individually adjust the timing of the stepped operation of the former and filler machine and conveyer controlled thereby.

9. The high-speed carton former, filler and sealer machine of claim 8 in which the containers are plastic bottles.

10. A high-speed carton former, filler and sealer machine comprising, a forming machine adapted to form thermoplastic coated carton blanks of paperboard from carton blanks in a flattened condition to an erected form with open tops flaps adapted to be folded and sealed to seal the carton; control means for controlling the operation of the carton forming machine in a stepped type operation to discharge erected carton blanks in the condition for,filling and sealing and including circuit means for energizing the control means to provide such stepped operation; a filling machine adapted to receive and fill erected carton blanks, said filling machines being positioned adjacent the forming machine to receive erected carton blanks discharged therefrom; control means for controlling the operation of the filling machine including circuit means to provide stepped operation of the filling machine; a capping mechanism included in the filling machine and adapted to cap containers filled by the filling machine; a conveyer adapted to supply the filling machine with an alternate source of containers which utilize the capping mechanism, control means including circuit means for controlling stepped operation of the conveyer, said conveyer being adapted to be positioned such that one extremity of the same is disposed adjacent the filler machine and the forming machine to discharge containers to the filling machine to be filled and capped thereby; and supervisory control means included in part in the control circuit for the filling machine and in part for the control circuits of the forming machine and the conveyer to slave the operations of the respective machines to the slowest operating machine.

11. The high-speed carton former, filler and sealer machine of claim 10 in which the control circuits for the conveyer, forming machine, and filling machine include interlocking circuitry to provide for operation of the conveyer with the filling machine and capping mechanism and operation of the forming machine with the filling machine in a fill and seal operation.

12. The high-speed carton former, filler and sealer of claim 11 in which the supervisory control means permits stepped operation of the forming machine and conveyer selectively only in accord with the stepped operation of the filling machine.

13. The high-speed carton former, filler and sealer machine of claim 12 in which the filling machine includes separate means for capping and sealing and in which the sealing means and the capping mechanism are adapted to be pivoted out of engagement With the erected carton blanks and containers filled by the filling machine selectively whenever such seal means and capping mechanism is not in use.

References Cited UNITED STATES PATENTS 6/1964 Johnson et a1 53-168 3/1966 Fivet 53-20 1 X 

1. A HIGH-SPEED CARTON FORMER, FILLER AND SEALER MACHINE COMPRISING: A FORMING MACHINE ADAPTED TO FORM THERMOPLASTIC COATED BLANKS OF PAPERBOARD FROM CARTON BLANKS INA FLATTENED CONDITION TO AN ERECTED CONDITION BY OPENING THE BLANKS, BENDING AND FOLDING THE BOTTOM FLAPS OF THE SAME, HEATING AND SEALING THE BOTTOM FLAPS, AND BENDING THE TOP FLAPS OF THE ERECTED CARTON PREPARATORY TO FILLING AND SEALING OF THE SAME; CONTROL MEANS FOR CONTROLLING THE OPERATION OF THE CARTON FORMING MACHINE IN A STEPPED TYPE OF OPERATION; A FILLING MACHINE ADAPTED TO RECEIVE AND FILL AND CARTON BLANKS INCLUDING A FILLER MACHANISM, A HEATER AND FLAP FOLDER, A FLAP SEALER, AND A CAPPING MECHANISM; A SECOND CONTROL MENAS FOR CONTROLLING THE OPERATION OF THE FILLING MACHINE IN A STEPPED TYPE OF OPERATION; A CONVEYER ADAPTED TO SUPPLY THE FILLING MACHINE WITH AN ALTERNATE SOURCE OF CONTAINERS WHICH UTILIZE THE CAPPING MECHANISM, THIRD CONTROL MEANS FOR OPERATING THE CONVEYER IN A STEPPED TYPE OF OPERATION; THE SECOND CONTROL MEANS OF THE FILLING MACHINE HAVING A SUPERVISORY CONTROL INCLUDED IN PART IN THE FIRST AND THIRD CONTROL MEANS TO SELECTIVELY LIMIT THE STEPPED OPERATION OF THE FORMING MACHINE AND THE CONVEYOR IN ACCORD WITH THE OPERATION OF THE FILLER MACHANISM OF THE FILLER MACHINE. 